Noblelift PSE12BSL Service Manual

Psk electric stacker

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Service Manual

PSK Electric Stacker

（PSE12BSL / PSE12NSL）

WARNING

Do not use the electric truck before

reading

and

operating instructions.

NOTE:

Keep for future reference.

This vehicle is for use in factory sites,

tourist attractions and playgrounds on

understanding

Service hotline：4008-836115

these

version 07/2024

PSE12BSL/PSE12NSL-SM-004-EN

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Summary of Contents for Noblelift PSE12BSL

Page 1 Scan for more information Service hotline：4008-836115 Service Manual PSK Electric Stacker （PSE12BSL / PSE12NSL） WARNING Do not use the electric truck before reading understanding these operating instructions. NOTE: version 07/2024 Keep for future reference. This vehicle is for use in factory sites,...
Page 2 FOREWARD Before operating the electric stacker, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation of the truck may create a danger situation. This handbook describes the usage of different electric stackers. When operating and servicing the truck, make sure, that it applies to your type.
Page 3 Content CORRECT APPLICATION DESCRIPTION OF THE STACKER a. Overview of the main components b. Main technical data c. Description of the safety devices and warning labels 3.WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS a. Warning label definition vocabulary COMMISSIONING, TRANSPORTING, DECOMMISSIONING a.
Page 4 b. Lubrication point c. Check and refill hydraulic oil d. Checking electrical fuses e.Removing, reattaching guarding f.Disassembly/assembly instructions f-1. Standard torque f-2.Standard torque for fastening accessories TROUBLE SHOOTING WIRING/ CIRCUIT DIAGRAM Electrical circuit diagram b.Hydraulic circuit c.Schematic diagram of braking system Electronic Systems a-1 Overview b-1.BATTERY SAFETY, CHARGING AND REPLACEMENT...
Page 5 a-1-1 Component a-2 Driver Assembly a-2-1 Appearance a-2-2 Operation a-2-3 Drive motor disassembly/assembly and testing a-2-4 Drive wheel disassembly/installation 15.Hydraulic System a-1 Overview a-1-1 Component a-2-3 Disassembly/Installation of Pump Motor and Hydraulic Pump a-2-4 Pump Motor Disassembly/Assembly and Test a-3 Hydraulic Tanks and Filters a-3-1 Appearance a-4.Troubleshooting a-4-1 Pump motor...
Page 6 CORRECT APPLICATION It is only allowed to use this electric stacker according to this instruction handbook. The trucks described in this handbook are self-propelled pedestrian controlled electric power stackers, with electrically powered lifting function. The trucks are designed for stacking operations in dedicated racking by lifting and lowering the palletized loads up to the desired lifting heights.
Page 7 DESCRIPTION OF THE STACKER Overview of the main components Fig 1：Overview of main components Mast 10. Cover 20. Pin-code panel Load Backrest, Fork 11. Cover 21. LCD carriage 12. Main cover 22. Emergency button Fork 13. Cover 23. Spring cord Load roller assembly 14.
Page 8 Overview of the main components (20CE/EN1175:2020) Fig 2：Overview main components Mast 10. Cover 20. Pin-code panel Load Backrest, Fork 11. Cover 21. LCD carriage 12. Main cover 22. Emergency button Fork 13. Cover 23. Spring cord 14. Cover 24. Button switch (Lithium) Load roller assembly 15.
Page 9 Main technical data Fig. 3: Technical data Table1: Main technical data for standard version...
Page 10 Type sheet for industrial truck acc. to （VDI2198） PSE12BSL PS E12NSL Manufacturer`s type designation 3600 / 3564 Power (battery ,diesel, petrol, gas, Battery manual) Operator type Pedestrian Load Capacity / rated load Q (t) Load centre distance c (mm) Load distance ,centre of drive axle to fork...
Page 11 4.35 Turning radius Wa (mm) 1345 Travel speed, laden/ unladen Km/h 4.2 / 4.5 Lift speed, laden/ unladen 0.11 / 0.14 Lowering speed, laden/ unladen 0.13 / 0.11 Max. gradeability, laden/ unladen 4 / 10 5.10 Service brake 电磁制动 Drive motor rating S2 60min 0.65 Lift motor rating at S3 7.5% Battery acc.
Page 12 Description of the safety devices and warning labels A Crane hook label B Warning decal: Do not step under or on the forks C Residual lift capacity sticker D Never reach through E Identification plate (ID-plate) F Sticker to read and follow these instructions G Sign of filling point H “No passengers”...
Page 13 WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS DO NOT  When driving outdoors, the stacking operation lifts the cargo higher than the lifting point  Put foot or hand under or into the lifting mechanism.  Allow other person than the operator to stand in front of or behind the truck when it is moving or lifting/lowering....
Page 14 Warning label definition This manual uses the following three warning labels: "Danger", "Warning" and "Caution". Each label is designed to show the reader the severity and nature of the potential hazards, the consequences, and preventive measures to prevent the hazards. You will find these labels throughout this manual. Make sure you pay attention to them carefully, as they are included for your safety.
Page 15 vocabulary  The following are the terms and descriptions used in this service manual Item Descriptions Accelerator A device that converts mechanical motion to an analog voltage mode and transmit to a controller to control the speed at which a vehicle is driven Actuator A device (e.g.
Page 16 Handheld A maintenance tool program to calibrate and diagnose CURTIS controllers of trucks. programmer Parking Brake A pair of brakes that electromagnetically activate their respective motors upon the stationary of the vehicle. Encoder A device that detects the direction and speed of a motor to produce a pulse signal. A device that generates an airflow to cool an electric motor and a controller..
Page 17 Controller Unit Safety Valve A valve that limits the pressure of the hydraulic system by releasing excess oil Resistance A component made of a material with a specific current impedance. Return Filter A filter to collect contaminants in oil returned to a hydraulic tank Rotor A part of rotating motor.
Page 18 COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning Table 2: Commissioning data Type PSE12BSL / 3600 PSE12NSL / 3600 Commissioning weight [kg] Dimensions [mm] 3600 3600 Type PSE12BSL / 3600 PSE12NSL / 3600 Commissioning weight [kg] Dimensions [mm] 3600 3600 After receiving our new stacker or for re-commissioning you have to do following before (firstly) operating the truck: ...
Page 19 Fig. 5: Lifting with a crane Fig. 6: Fixing points Transportation DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck securely. Fasten the truck according to Fig. 6 by fixing dedicated lashing belts to chassis, Fork carriage and mast, and fasten the other side at the transporting truck.
Page 20 DAILY INSPECTION This chapter describes pre-shift checks before putting the truck into operation. Daily inspection is effective to find the malfunction or fault on this truck. Check the truck on the following points before operation. Remove load from truck and lower the forks. DO NOT USE THE TRUCK IF ANY MALFUNCTION IS FOUND.
Page 21 Make sure, that the load is palletized and stable and that the daily inspection is carried out. PSE12BSL：Pull out the emergency button ( 22), type the password on pin-code panel (20) and press √ button to start the truck. PSE12NSL：Pull out the emergency button ( 22), Press the button switch, and a green light will appear on the switch (Fig.8), type the password on pin-code panel...
Page 22 a. Parking DO NOT PARK THE TRUCK ON INCLINED SURFACES The truck is equipped with an electromagnetic fail safe stopping and parking brake. PS E12BSL: Always lower the forks fully. Press the emergency switch (22). PS E12NSL: Always lower the forks fully. Press the button, green LED ring is off (Fig.8), and press the emergency switch (22).
Page 23 e. Travelling TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL DO NOT TRAVEL ON INCLINES MORE THAN SPECIFIED WITH THE TECHNICAL DATA. TRAVELLING IS ONLY ALLOWED IF THE FORKS ARE LOWERED DOWN TO THE LIFTING POINT (<300MM). Fig 11: Operating direction After starting the truck by activation from Pin-code panel carefully move the tiller to the operating zone (‘F’, fig.11).
Page 24 f. Steering Steering system is a set of devices that turn vehicles to the left or right. In this model, the steering system is a mechanical structure consisting of a tiller shaft (20) and a driving shaft (6), which are connected by a wire rope chain (7).
Page 25 g. Braking PLEASE CHECK THE BRAKING DISTANCE WITH TRUCK BEFORE OPERATION THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITIONS AND THE LOAD CONDITIONS OF THE TRUCK The braking function can be activated on several ways:  By moving the accelerator button (28) back to the initial ‘0’ position or by releasing the button, the regenerative braking is activated.
Page 26 h. Malfunctions If there are any malfunctions or the truck is inoperative, please stop using the truck and activate the emergency button (22) by pushing it. If possible, park the truck on a safe area and press the X button of pin-code panel. Inform immediately the manager and, or call your service.
Page 27 k. Leg adjustment  Not fixed and not properly adjusted legs can lead to dangerous accidents.  There is leg injury risk when adjusting the legs.  Tighten the positioning bolt (39) after adjusting the legs.  When adjusting the legs, please pay attention that the number of positioning holes (38) exposed on each side of the legs should be same.
Page 28 IP grade：IP65 Unlock & Main functions PSE12BSL is equipped with a password ignition switch to support a set of manual password operation. A password consists of four digits, ranging from 0 to 9。 PSE12NSL is equipped with password ignition switch and ID card functions. Supports up to 5 ID cards and a set of manual password operations.
Page 29 Maintain safety Pre-maintenance Ensure that the vehicle is in a clean, open environment and not affected by traffic and other people. Ensure that the vehicle is parked safely and that the vehicle does not move suddenly. Place wooden props in front of and behind the wheels and make sure the parking brake is properly engaged.
Page 30 Compressed air hazards When cleaning, please wear a protective mask, protective clothing and protective shoes. When cleaning, the maximum air pressure must be lower than 205 kPa (30 psi). Hydraulic oil hazards Please carefully follow the instructions below to carry out safety tips on hydraulic system maintenance.
Page 31 Risk of fire and burns To avoid burns, please pay attention to the hot parts on the machine just stopped and the hot oil in the pipes and tanks. All hydraulic fluids, most lubricants and some coolant mixtures are flammable. If the pipe is loose or damaged, a fire may occur.
Page 32 REGULAR MAINTENANCE  Only qualified and trained personnel are allowed to do maintenance on this truck.  Before maintaining, remove the load and lower the forks to the lowest position.  If you need to lift the truck, follow chapter 4 b by using designated lashing or jacking equipment.
Page 33 a. Maintenance checklist Interval(Month) Table 3: Maintenance checklist Hydraulic  Check the hydraulic cylinder for damage noise and leakage  Check the hydraulic joints for damage and leakage  Inspect the hydraulic oil level, refill if necessary  Replace the hydraulic oil ( 12 month or 1500 working hours ) ...
Page 34  33 Check the horn function  34 Check the air gap of the electromagnetic brake  35 Test the emergency braking  36 Test the reverse and regenerative braking  37 Test the safety (belly) button function  38 Check the steering function ...
Page 35 Check and refill hydraulic oil It is recommended to use hydraulic oil in connection with average temperature: Environment –5℃~25℃ >25℃ temperature Type HVLP 32， HLP 46， DIN 51524 DIN 51524 Viscosity 28.8-35.2 41.4 - 47 Amount 5L (depends on specific model) Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company.
Page 36 Removing, reattaching guarding DO NOT USE THIS TRUCK, IF THE GUARDING IS DAMAGED OR NOT CORRECTLY ASSEMBLED! If the guarding needs to be removed - de-attach holding clamps carefully. For reattaching place the screen to its correct position and place holding clamps back to their original position. If you need to replace parts, please call your service partner.
Page 37 Keep the gap Ensure that the installed gaskets and washers produce the required specified clearance value Remove press parts Remove any dents or marks caused by hammering and polishing the area. If you loose any press-fitted parts, please determine and eliminate the cause to avoid problems during the assembly process.
Page 38 Figure Figure Check during assembly in each step of the assembly process, check and record each part number Reassemble the gasket Install gaskets and washers in the same positions as before, and then check if the gap is correct. Assembly adjustment link If there is no need to adjust, please assemble them to the same length as before Assemble press parts Repair scratches and dents as needed, and keep parts clean before insertion.
Page 39 Check the surface of the oil seal lip for scratches. If there are scratches, replace the oil seal. When inserting the oil seal, use guides and clamps to avoid damage to the oil seal. After inserting the oil seal, check the inclination (inclination tolerance: 0.2 mm/00 mm, diameter 0.008 inch/3.937 inch).
Page 40 end of the pipe. Place the end of the pipe against the counterbore in the main body of the fitting and tighten it until the nut is above the last thread on the main body. Just remove the accessory and install it again, and the remaining space will be used.
Page 41 f-1. Standard torque Standard torque of bolts and nuts Be careful to avoid mixing metric and imperial size fasteners. Mismatch or incorrect The fasteners may cause vehicle damage or malfunction, or may cause personal injury. If necessary, exceptions to these torques can be given in the service manual.
Page 42 For Metric Fasteners...
Page 43 f-2. Standard torque for fastening accessories Standard torques for O-ring surface seal fittings...
Page 45 Thread fittings for air conditioning and conical pipes...
Page 46 TROUBLE SHOOTING If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 5: Trouble shooting TROUBLE CAUSE REPAIR Lift only the max. capacity, Load weight too high mentioned on the ID-plate Battery discharged Charge the battery Check and eventually replace Load can’t be Lifting fuse faulty the lifting fuse...
Page 47 WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram FU1 : 60 A FU2: 150 A FU01: 10 A Fig 17: PSE12BSLCircuit Diagram...
Page 48 FU1: 60 A FU2: 150 A FU01: 10 A FU02:1.5 A Fig .18: PSE12NSLCircuit Diagram...
Page 49 Table 6: Electrical Symbol Descriptions Code Item Code Item Code Item tiller Horn Emergency stop switch controller Oil pump contactor Upper limit switch signal fuse 60A Oil pump motor Push button switch fuse 150A Traction motor Charger FU01 Insert fuse 10A Interlock switch USB charger Lifting deceleration...
Page 50 Circuit Diagram (EN1175:2020) FU1 : 60 A FU2: 150 A FU01: 10 A 19: PSE12BSL Circuit Diagram (EN1175:2020)
Page 51 FU1: 60 A FU2: 150 A FU01: 10 A FU02: 1.5 A Fig .20: PSE12NSL Circuit Diagram (EN1175:2020)
Page 52 Table 7: Description of electrical diagram Code Item Code Item Code Item Tiller Traction motor Button switch Controller Inter lock Charger Fuse Lifting speed limit USB port switch Battery Steering speed limit Brake switch Horn DC power switch Lowering valve Oil pump contactor Limit switch Pump motor...
Page 53 b. Schematic diagram of braking system Fig 22: Braking schematic diagram...
Page 54 Only qualified personnel are allowed to service or charge the batteries. The instructions of this handbook must be observed.  PSE12BSL is lead acid battery, PSE12NSL is lithium battery  Recycling of batteries undergoes national regulations. Please follow these regulations.
Page 55 b-1-1 Lithium battery appearance and specifications...
Page 56 Item Parameter Note Specification 24V60Ah 8-LFP-60-EV-NOB Nominal Voltage 25.6V Rated Capacity 60Ah 0.5C discharge Reference weight About 17kg Discharge Maximum Continuous Discharge 100A Current Maximum pulse discharge 150A No more than 10 seconds current Discharge cut-off voltage ≥22V Discharge Standard Charging Current Maximum Charging Current Charging voltage 28~28.8V...
Page 57 b-1-2 Safety Instructions (lithium battery) Failure to follow the below requirements may cause damage to your property, cause injuries or death. Measures to prevent ignition  It is forbidden to work at temperatures over 60 ℃.  It is forbidden to place it beside heat sources, such as stoves, fireplaces, etc. ...
Page 58 Ambient temperature Remaining discharge capacity of battery pack 25℃ 100% 0℃ -20℃ -30℃ Note: Although the battery can be discharged at very low temperature, it is easy to generate condensate during the charging process, which will damage the internal electronic devices of the battery and create unpredictable hidden dangers.
Page 59 Battery State of charge Batteries are represented by 10 LED display segments, each representing 10% of the power. As the batteries discharge gradually, the LED lights go out in turn, but only one at a time Turtle Symbol: It is normally off, when it appears (fixed) it shows activation of the “soft” mode of the truck, in which maximum speed and acceleration are reduced.
Page 60 Lithium charger Table 9: LED light scenario LED light signal Function Battery discharge Orange Charging Green Battery full Introduction WT2425ZMB type charger, the charger is a high-efficiency, fast, small volume, floor-mounted charging equipment with CAN communication. The charger is a two-phase AC 220V voltage input with forced air-cooling cooling method, with input over-voltage, under-voltage, output over-voltage, under-voltage, over-current, output short-circuit, fan fault protection functions, and also meets RoHS and CE requirements.
Page 61 Lithium battery charger indicator light description Indicator label No-load indication Red green lights flashing alternately Battery indicator Red light flashes at 1s interval and the battery power is less than 80%. Yellow light flashes at 1s interval, battery power > 80%; Green light flashes at 1s interval, battery power 100% error indication...
Page 62 Loosen the battery stopper and remove it without touching the positive and negative battery terminals. Watch the battery as it is moved out without touching the upper electrical dashboard. Remove the lower second battery (PSE12BSL only) in the same manner. Installation is the reverse procedure of disassembly. Please connect the positive side of the battery first.
Page 63 b-1-6.Lithium Battery Failure Analysis and Explanation Battery pack system fault repair table Fault Analysis Testing methods Fault confirmation Solution Type 1. The measurement of infinite resistance indicates that the CAN communication 1. Check the alarm code on harness is the vehicle display to disconnected.
Page 64 1、Measure the charging Check the socket harness 12V, GND, Improper conduction charging CANH, CNAL harness is harness Battery 1. Improper conduction normal pack communication 2, connect the charger, does not with vehicles; check the charger display charge, 2. Damage to fault code, shut down the switch internal...
Page 65 b-2. Emergency switch b-2-1 Appearance and specifications specification ZDK32-350-1 (EN1175:2020)
Page 66 b-2-2 Function The emergency stop switch is used to cut off the current in the electrical system in case of emergency, thus stopping the operation of the vehicle. When pressed, all DC and AC circuits are open. DC Circuit Open Circuit Once the emergency stop switch is opened, the positive terminal of the battery is disconnected from the key switch, thus cutting off power to all loads supplied through the key switch.
Page 67 Disassembly and installation Preliminary Steps 1 Park the vehicle safely and remove the housing. 2 Turn off the key switch. 3 Disconnect the battery connector. Procedure 1). Disconnect the pushbutton switch (8) and the USB power cable. 2). Remove the emergency stop switch cap screw (12) and remove the emergency stop switch cap (11). 3).
Page 68 b-3 controller and related devices b-3-1 Appearance 1). Controller Curtis 1212C Logical part plug-in: 14 core Molex Mini-Fit Jr., P/N 39-01-2140 Electromagnetic brake plug-in: 2 core Molex Mini-Fit Jr., P/N 39-01-2020; Handheld Programming Port Plugin: 4 core Molex Mini-Fit Jr., P/N 39-01-2040;...
Page 69 b-3-2 Functions The controller is connected via the following sensors, switches, relays and actuators. Key switch Power switch throttle tiller proximity switch Emergency reverse switch Hydraulic control switches By correctly setting the motor technical parameters and control technical parameters and function values of the controller, the safe and efficient operation performance and complete operation functions of the electric vehicle can be achieved.
Page 70 b-3-3 Test A. Controller Measure the diode voltage of the AC MOSFET circuit inside the controller to check whether it is burned or damaged. Remove the cables and harnesses connected to the controller and completely discharge the internal capacitor (discharge the B+ and B- terminals with a resistor 30Ω/5W). Use a multimeter to measure according to the table below and check whether it is normal.
Page 71 Item Multimeter terminals Normal value range test Black test Measurement Measurement lead lead of polarity value resistance value 40KΩ+ 80KΩ+ 80KΩ+ 60KΩ+ 0.3-0.6V 0.3-0.6V Multimeter pull to Ω file (resistance value determination) Multimeter pull to diode file (polarity value determination) b-3-4 Disassembly and installation Access to the control panel 1).
Page 72 13 Tiller head a-1 Function The tiller head controls some of the vehicle's movements through up and down buttons, belly switches, turtle buttons, throttle and combination locks and controller interplay. A combination lock (18) B lift and lower (28,29) C belly switch (16) D throttle (26) E turtle switch (30) F horn switch (27)
Page 73 a-2 Tiller head Inspection Use a multimeter to measure the resistance between pin 4 and pin 5 of III Rated resistance：120.0Ω Use a multimeter to measure the on/off of the belly switch and horn switch respectively. If not and CAN resistance is not correct, please replace the tiller a-3 Tiller Head disassembly and Installation Preliminary steps 1) Remove the housing to gain access to the interior of the vehicle...
Page 74 a-4 Tiller Proximity Switch disassembly and Installation Preliminary steps 1) Park the vehicle safely. 2) Turn off the key switch and emergency stop switch. Procedure 1) Press down on the tiller and disconnect the wiring harness connection of the proximity switch. 2) Remove the fixing screw (14) of the proximity switch and remove the proximity switch.
Page 75 a-6 Tiller disassembly and Installation Preliminary steps 1) Park the vehicle safely. 2) Turn off the key switch and emergency stop switch. Procedure 1) Press down on the tiller to disconnect the proximity switch and the harness of the tiller. 2) Remove the set screw (10) at the lower end of the gas spring.
Page 76 14 Drive/Brake System a-1 Overview a-1-1 Component The drive/brake system includes the following: 1) The drive motor controlled by the controller transmits the rotational force to the drive shaft (electric power mechanical power). 2) The drive shaft converts the rotational force transmitted from the drive motor into torque and speed suitable for driving through its gear set and sends them to the corresponding wheels (mechanical power).
Page 77 Drive Assembly disassembly and Installation Preliminary steps 1) Park the vehicle safely and remove the case 2) Turn off the key and emergency stop switch. 3) Disconnect the battery connector. Procedure 1) Remove the steering wire rope assembly (7). 2) Remove the steering shaft screw (5) and remove the steering shaft (6) 3) Lift the whole vehicle, the weight of the whole vehicle is 585KG.
Page 78 a-2-3 Drive motor disassembly/assembly and testing Disassembly/Assembly 1) Remove the electromagnetic brake fixing screws and remove the electromagnetic brake (3) 2) Remove the electromagnetic brake gear. 3) Remove the drive case screws and remove the case. 4) Loosen and withdraw the motor fixing screw. 5) Set up the motor in the air, and punch out the motor downward.
Page 79 a-2-4 Drive wheel disassembly/installation preliminary steps 1) Park the vehicle safely and remove the case 2) Turn off the key and emergency stop switch. 3) Disconnect the battery connector. procedure 1) Lift the vehicle safely with a hoist. 2) Disconnect the connecting wire of the driving motor. 3) Loosen and withdraw the driving wheel fixing screw (9) 4) Push out the drive wheel with screws.
Page 80 that corrections can be made to eliminate the fault. Change to tires with less friction Excessive battery drain from the hydraulic system due to lift failure, or incorrect hydraulic conditions for the duty cycle Check the mast for restrictions during operation. After a work shift, the vehicle works beyond its designed capacity without available power: The vehicle has a battery that is too small: Neither...
Page 81 a-3-2 Driver box Problem Possible Cause Out of lube: Meet the correct amount of lubricant Using non-standard oils: Replace oil with standard oil. Gears are damaged or dented: Noise or vibration in the Change the gear. gearbox Bearing damage: Replace bearings. Loose mounting bolts: Apply thread compound to the threads of the bolt and retorque to the specified torque.
Page 82 15.Hydraulic System a-1 Overview The hydraulic system is composed of working oil pump, lifting cylinder and piping and other components. The hydraulic oil is supplied by the oil pump directly connected to the motor. The oil pump pumps the hydraulic oil to the cylinder.
Page 83 a-2 Pump assembly a-2-1 Appearance and specification Item specification Power 0.8KW Speed 1618rpm Frequency 55.5hz Insulation level a-2-2 Inspection The pump motor transmits power electrically to the main hydraulic pump in order to pump the hydraulic fluid to operate the hydraulic system. The pump motor is connected to the controller via a motor contactor.
Page 84 Pump motor contactor Inspection: For the pump motor contactor, as shown in Fig. and check that it measures the specified value. a-2-3 Disassembly/Installation of Pump Motor and Hydraulic Pump Note: Do not put any pressure on the motor when assembling and disassembling the hydraulic pump Preliminary Steps 1) Lower the fork to the bottom, press the down button several times to eliminate the residual...
Page 85 a-2-4 Pump Motor Disassembly/Assembly and Test Disassembly/Assembly 1) Disconnect the pump motor contactor connection and remove the contactor. 2) Loosen the fixing screws of the pump motor and the pump. 3) Take out the motor from the vertical pump station upwards. 4) Perform the above steps in reverse order to assemble the pump motor NOTE: Before reassembling the motor, you can test its parts as follows.
Page 86 a-3 Hydraulic Tanks and Filters a-3-1 Appearance 1) Lower the fork to the top, press the down button several times to eliminate the residual pressure in the hydraulic system 2) Open the casing and disconnect the battery. 3) Prepare and pan. DANGER! Hot oil and components may cause personal injury, do not allow hot oil and components to come into contact with the skin...
Page 87 a-4. Troubleshooting a-4-1 Pump motor Problem Display Possible Cause Poor connection or blown fuse. Check battery connection. Check key fuse. Check the hydraulic pump motor for possible blown fuses. Key switch, upper limit switch, line contactor not closed. Turn off the key switch. Use a multimeter to check power flow through the key switch, line contactor coil, and line contactor.
Page 88 a-4-2 Hydraulic pump Problem Display Possible Cause The oil level is low. The oil is very thick (too viscous) The pump inlet line is restricted. Noise in the pump. Wear parts in the pump. The oil is dirty. Air leaks into inlet line. The oil level is low.
Page 89 16 LIFTING SYSTEM a-1 Overview a-1-1 Component The lifting system is powered by the main hydraulic pump. Forks: Two forked objects to support the load Chains: Parts that lift carriages and masts Lift Cylinder: Single-acting cylinder pulls back the chain of the carriage Mast: The vertical structure at the front of a forklift that extends and retracts to raise and lower loads a-2.
Page 90 Cylinders After receiving hydraulic fluid from the pump station, the cylinder rod extends and pushes the inner mast upward, while the forks are pulled by the lift chain, which is connected to the outer mast to lift with the chain. Lowering If the operator presses and holds the lowering button, the oil output from the cylinder will start to flow to the tank by gravity.
Page 91 a-2-2 fork A) Fork inspection Forks should be inspected at least every 12 months. If the vehicle is used on multiple shifts or heavy duty work, it should be inspected every six months. 1) Check the forks carefully for cracks. Particular attention should be paid to the heel section, all weld areas and mounting brackets.
Page 92 Lift chain disassembly/installation 1) Raise the fork and place a sleeper under it. 2) Lower the forks onto the sleepers to release tension from the main lift chain. 3) After removing the cotter pin (5), pull out the cotter pin (4) to remove the chain from the chain anchor. 4) Remove the bolts and washers connecting the chain with the mast, and then take out the chain.
Page 93 17.CURTIS Handheld Programmer a-1 Operation Cautions The prompt function of the programmer is designed for the convenience of vehicle inspection and maintenance, Adjustments to the controller parameters are not allowed without the approval of the vehicle manufacturer，so as to avoid vehicle and personal safety accidents.
Page 94 Warning： The control system will affect the performance of vehicle's acceleration, deceleration, hydraulic system and brakes. Hazardous conditions may occur if the vehicle control system is incorrectly programmed or beyond safety limit. Only the vehicle manufacturer or authorized service agent may program the control The programmer has two interfaces with a battery box and a memory card slot, of which one is used to communicate with electric control, and the other is used to communicate with PC.
Page 96 Function keys The three keys will be blank because the function of the three keys is based on the specified content. At any given time, the functions of the buttons are displayed on the LCD screen above. Directional arrow key The information displayed can be selected by pressing up, down, or left or right through 4 directional keys.
Page 97 Nine main menus Programmin Favorites System Information Programme r Setting Paramet Monitor Manager Menu Plot & Log Editing 3. Fault diagnosis menu In the main menu, Select the "Diagnostics" Fault diagnosis icon and press the corresponding function key to enter the Fault diagnosis menu, which includes two folders: "Present Errors" and "Fault History"...
Page 98 "Clear All" is used to Clear the history failure folders. A function key will be highlighted separately if there is a history failure in the history failure folder, and will be grayed out if there is no history failure. 4. Programming edit menu In the main menu, Select the "Programming"...
Page 99 Parameters can be adjusted or modified in two ways: one is in the parameter list page as shown in the figure below; The other is through the parameter edit page as shown below...
Page 100 18.Troubleshooting for Each Fault Code Countermeasures of fault codes for 1212C-2503 controller NL-200Handle error check list Error description Error reason Source 1212C-2503 LOW_BDI Low power controller 1212C-2503 PUMP_SRO_FAULT Lift / lower action key start switch controller operating sequence is not correct including 1212C-2503 SRO_FAULT moving,lock,start switch...
Page 101 1212C-2503 MOTOR_SHORT Motor short circuit controller 1212C-2503 MOTOR_OPEN Motor open circuit controller CONTROLLER_OVERCURR 1212C-2503 Controller overcurrent controller MOTOR_TEMP_HOT_CUTB 1212C-2503 Motor hot cutback controller CONTROLLER_OVERTEMP 1212C-2503 Controller overtemp. Cutback _CUTBACK controller CONTROLLER_UNDERTEM 1212C-2503 Controller low temp. controller CONTROLLER_SEVERE_O 1212C-2503 Controller severe high temp. VERTEMP controller 1212C-2503...
Page 102 Lower fault Lowering button fault Tiller BMS Communication Outage BMS Communication overtime Tiller Over Voltage Battery high voltage Li-battery Over Discharge Battery over discharging Li-battery Communication Outage Battery Communication overtime Li-battery Under Voltage Battery low voltage Li-battery Over Current Battery over current Li-battery Over Temperature Protect Li-battery...
Page 103 Steering Angle Pot 21-4 wiring fault Incorrect throttle HPD Sequencing operation Throttle 1212E Controller 22-1 defective Main Relay Welded Main relay defective 1212E Controller 23-1 Main relay defective 24-1 Incorrect relay pull in Main Relay Did Not Close 1212E Controller voltage setting 24-2 25-1...
Page 104 53-4 Incorrect operation 54-1 sequence 54-2 Switch defective 54-3 PUMP SRO Fault 1212E Controller Incorrect parameter 54-4 settings 54-5 EMR switch defective 55-1 Incorrect operation EMR SRO Fault 1212E Controller 55-2 sequence Incorrect parameter 55-3 settings 56-1 Incorrect operation 56-2 Creep SRO Fault 1212E Controller sequence Cost...
Page 105 Tiller Turtle speed button failure, Turtle Mode fault Tiller speed button detected closed before power on. Rise button failure, the rise button is detected Lift fault Tiller as being pressed before the power is turned on. Faulty drop button, the drop button is detected Lower fault Tiller...
Page 106 Battery communication Communication Outage timeout, communication Lithium Battery timeout with controller Battery voltage is too low, 1, long-term storage, not in time to charge. 2, the battery Under Voltage Lithium Battery internal cell damage, resulting in the inability to charge into the power.

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